Transactions of Materials and Heat Treatment

Title：Simulation and experiment on forging process for hollow gear sleeve of automotive gearbox

Authors： Chai Huili

Unit： College of Automotive Engineering Shanxi Vocational University of Engineering and Technology

KeyWords： 25CrMo4 alloy steel hollow gear sleeve multi-station cold forging constitutive model fracture model

ClassificationCode：TG376.3

year,vol(issue):pagenumber：2025,50(7):36-43

Abstract：

For the hollow gear sleeve of automotive gearbox, a multi-station cold forging process was studied to address the current problems of complex process, large material processing allowance, poor product quality and unsatisfactory production efficiency, and the cold forging scheme of hollow gear sleeve was designed. Then, the corresponding forging simulation model was established. Meanwhile, the constitutive model of the actual forging material was studied. Furthermore, the process simulation was completed by Deform-3D, and the forming process, forming result and flow lines in cross-section of gear sleeve at each stage were analyzed to evaluate the feasibility of the process. In addition, the critical fracture damage value of material was determined by combining compression experiment with numerical simulation, and an accurate fracture prediction model was established. Based on this, the fracture risk of gear sleeve at each stage was evaluated, and the forging test of gear sleeve was completed. The research results show that the test results are highly consistent with the simulation prediction results. The tooth shape and thin wall are fully formed, the hole wall is smooth, and there are no defects such as missing materials, cracks, scratches, etc., which verifies the reliability of the process.

Funds：

山西省基础研究计划（自由探索类）；2022年度青年项目(202203021222327)

作者简介：柴慧理（1970-），男，学士，副教授 E-mail：92K1Q@aliyun.com

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